Classifications

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  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J12/00—Chemical processes in general for reacting gaseous media with gaseous media; Apparatus specially adapted therefor
  • B01J12/007—Chemical processes in general for reacting gaseous media with gaseous media; Apparatus specially adapted therefor in the presence of catalytically active bodies, e.g. porous plates
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  • B01J15/00—Chemical processes in general for reacting gaseous media with non-particulate solids, e.g. sheet material; Apparatus specially adapted therefor
  • B01J15/005—Chemical processes in general for reacting gaseous media with non-particulate solids, e.g. sheet material; Apparatus specially adapted therefor in the presence of catalytically active bodies, e.g. porous plates
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  • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
  • B01J19/0006—Controlling or regulating processes
  • B01J19/0013—Controlling the temperature of the process
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  • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
  • B01J19/24—Stationary reactors without moving elements inside
  • B01J19/248—Reactors comprising multiple separated flow channels
  • B01J19/2485—Monolithic reactors
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  • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
  • B01J19/32—Packing elements in the form of grids or built-up elements for forming a unit or module inside the apparatus for mass or heat transfer
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  • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
  • B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
  • B01J8/0242—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid flow within the bed being predominantly vertical
  • B01J8/0257—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid flow within the bed being predominantly vertical in a cylindrical annular shaped bed
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  • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
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  • C01B3/047—Decomposition of ammonia
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  • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
  • C01B3/22—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by decomposition of gaseous or liquid organic compounds
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  • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
  • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
  • C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
  • C01B3/34—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
  • C01B3/38—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts
  • C01B3/384—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts the catalyst being continuously externally heated
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  • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
  • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
  • C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
  • C01B3/34—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
  • C01B3/38—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts
  • C01B3/40—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts characterised by the catalyst
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  • C01C—AMMONIA; CYANOGEN; COMPOUNDS THEREOF
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  • C01C3/0208—Preparation in gaseous phase
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  • C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
  • C07C5/32—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with formation of free hydrogen
  • C07C5/327—Formation of non-aromatic carbon-to-carbon double bonds only
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  • C07C5/32—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with formation of free hydrogen
  • C07C5/327—Formation of non-aromatic carbon-to-carbon double bonds only
  • C07C5/333—Catalytic processes
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  • C07C5/32—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with formation of free hydrogen
  • C07C5/373—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with formation of free hydrogen with simultaneous isomerisation
  • C07C5/393—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with formation of free hydrogen with simultaneous isomerisation with cyclisation to an aromatic six-membered ring, e.g. dehydrogenation of n-hexane to benzene
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  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G35/00—Reforming naphtha
  • C10G35/04—Catalytic reforming
  • C10G35/06—Catalytic reforming characterised by the catalyst used
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  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G47/00—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions
  • C10G47/02—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used
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  • C01B2203/02—Processes for making hydrogen or synthesis gas
  • C01B2203/0205—Processes for making hydrogen or synthesis gas containing a reforming step
  • C01B2203/0227—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step
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  • C07C2523/54—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of noble metals combined with metals, oxides or hydroxides provided for in groups C07C2523/02 - C07C2523/36
  • C07C2523/56—Platinum group metals
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• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/30—Hydrogen technology
  • Y02E60/36—Hydrogen production from non-carbon containing sources, e.g. by water electrolysis

Definitions

• Embodiments of the invention relate to a reactor system and a process for carrying out steam reforming of a feed gas comprising hydrocarbons where the heat for the endo thermic reaction is provided by resistance heating.
• Endothermic reactions will often be challenged by how efficient heat can be trans- ferred to the reactive zone of the catalyst bed within a reactor unit.
• Conventional heat transfer by convection, conduction and/or radiation heating can be slow and will often meet large resistance in many configurations.
• This challenge can be illustrated with the tubular reformer in a steam reforming plant, which practically can be considered as a large heat exchanger with heat transfer as the rate limiting step.
• the temperature at the innermost part of the tubes of the tubular reformer is somewhat lower than the temperature outside the tubes due to the heat transfer rate through the walls of the tube and to the catalyst within the tubes as well as due to the endothermic nature of the steam reforming reaction.
• DE102013226126 describes a process for allothermal methane reforming with physical energy reclamation, wherein me thane is reformed by means of carbon dioxide to synthesis gas consisting of carbon monoxide and hydrogen.
• the starting gases CH 4 and C0 2 are conducted in a fixed bed reactor consisting of electrically conductive and catalytic particles, which is electrically heated to temperatures of about 1000 K.
• the conversion of the reactant gases and the generation of heat of the generated synthesis gas take place in the fixed bed reactor.
• An advantage of the invention is that the overall emission of carbon dioxide and other emissions detrimental to the climate may be reduced considerably, in particular if the power used in the reactor system is from renewable energy resources.
• Embodiments of the invention generally relate to a reactor system for carrying out an endothermic reaction of a feed gas, the reactor system comprising:
• a structured catalyst arranged for catalyzing the endothermic reaction of a feed gas, where the structured catalyst comprises a macroscopic structure of electrically con ductive material, where the macroscopic structure supports a ceramic coating and wherein the ceramic coating supports a catalytically active material;
• a structured catalyst arranged for catalyzing said endothermic reaction of a feed gas, said structured catalyst comprising an electrically conductive material and a catalyst material;
• the layout of the reactor system allows for feeding a pressurized feed gas to the reac tor system at an inlet and directing this gas into the pressure shell of the reactor sys tem.
• a configuration of heat insulation layers and inert mate- rial is arranged to direct the feed gas through the structured catalyst where it will be in contact with the catalyst material, where the catalytically active material will facilitate the steam reforming reaction.
• the heating of the structured catalyst will supply the required heat for the endothermic reaction.
• the product gas from the heated structured catalyst is led to the reactor system outlet.
• the close proximity between the catalytically active material and the electrically con ductive materials enables efficient heating of the catalytically active material by close proximity heat conduction from the resistance heated electrically conductive material.
• An important feature of the resistance heating process is thus that the energy is sup- plied inside the object itself, instead of being supplied from an external heat source via heat conduction, convection and radiation.
• the hottest part of the reactor system will be within the pressure shell of the reactor system.
• the electrical power supply and the structured catalyst are dimensioned so that at least part of the structured catalyst reaches a temperature of 850-1100°C when the endothermic reac- tion is the steam reforming reaction, a temperature of 700-1200°C when the endother mic reaction is the hydrogen cyanide synthesis, a temperature of 500-700°C when the endothermic reaction is dehydrogenation, a temperature of 200-300°C when the en dothermic reaction is the methanol cracking, and a temperature of ca. 500°C when the endothermic reaction is the ammonia cracking reaction.
• the surface area of the elec- trically conductive material, the fraction of the electrically conductive material coated with a ceramic coating, the type and structure of the ceramic coating, and the amount and composition of the catalytically active catalyst material may be tailored to the spe cific endothermic reaction at the given operating conditions.
• the electrically conductive material is a macroscopic structure.
• the term "macroscopic structure” is meant to denote a structure that is large enough to be visible with the naked eye, without magnifying devices.
• the dimen sions of the macroscopic structure are typically in the range of centimeters or even meters.
• the structured catalyst may comprise a single macroscopic struc ture or an array of macroscopic structures, where the macroscopic structure(s) sup ports) a ceramic coating supporting catalytically active material.
• the macroscopic structures may be electrically connected to each other; however, alternatively, the macroscopic structures are not electrically con- nected to each other.
• the structured catalyst may comprise two or more macro scopic structures positioned adjacent to each other.
• the macroscopic structure(s) may be extruded and sintered structures or 3D printed structures. A 3D printed macro scopic structure can be provided with or without subsequent sintering.
• the physical dimensions of the macroscopic structure may be any appropriate dimen sions; thus, the height may be smaller than the width of the macroscopic structure or vice versa.
• the macroscopic structure supports a ceramic coating, where the ceramic coating sup ports a catalytically active material.
• the term "macroscopic structure supporting a ce ramic coating" is meant to denote that the macroscopic structure is coated by the ce ramic coating at, at least, a part of the surface of the macroscopic structure. Thus, the term does not imply that all the surface of the macroscopic structure is coated by the ceramic coating; in particular, at least the parts of the macroscopic structure which are electrically connected to the conductors do not have a coating thereon.
• the coating is a ceramic material with pores in the structure, which allows for supporting catalytically active material on and inside the coating.
• the catalytically active ma- terial comprises catalytically active particles having a size in the range from about 5 nm to about 250 nm.
• the macroscopic structure has been manufactured by extrusion of a mix ture of powdered metallic particles and a binder to an extruded structure and subse- quent sintering of the extruded structure, thereby providing a material with a high ge ometric surface area per volume.
• the extruded structure is sintered in a re ducing atmosphere to provide the macroscopic structure.
• the macro scopic structure is 3D printed a metal additive manufacturing melting process, viz. a 3D printing processes, which do not require subsequent sintering, such as powder bed fu- sion or direct energy deposition processes. Examples of such powder bed fusion or di rect energy deposition processes are laser beam, electron beam or plasma 3D printing processes.
• the macroscopic structure may have been manufac tured as a 3D metal structure by means of a binder-based metal additive manufactur ing process, and subsequent sintered in a non-oxidizing atmosphere at a first tempera- ture Ti, where Ti > 1000°C, in order to provide the macroscopic structure.
• a ceramic coating which may contain the catalytically active material, is provided onto the macroscopic structure before a second sintering in an oxidizing atmosphere, in order to form chemical bonds between the ceramic coating and the macroscopic structure.
• the catalytically active material may be impregnated onto the ceramic coating after the second sintering.
• the heat transfer is effective, so that the structured catalyst can be very effi ciently heated.
• a compact reactor system in terms of gas processing per reactor sys tem volume is thus possible, and therefore the reactor system housing the structured catalyst may be compact.
• 3D print and “3D printing” is meant to denote a metal ad ditive manufacturing process.
• metal additive manufacturing processes cover 3D printing processes in which material is joined to a structure under computer control to create a three-dimensional object, where the structure is to be solidified, e.g. by sin tering, to provide the macroscopic structure.
• metal additive manufac turing processes cover 3D printing processes, which do not require subsequent sinter ing, such as powder bed fusion or direct energy deposition processes. Examples of such powder bed fusion or direct energy deposition processes are laser beam, electron beam or plasma 3D printing processes.
• the electrically conductive material is an embedded resistor em bedded in the catalyst material of the structured catalyst.
• This embedded resistor can be in any appropriate form of plates, spirals, rods, or similar, where the catalyst mate rial is positioned to surround, or in another way be in close contact to, the embedded resistor.
• the embedded resistor supports a ceramic coating, wherein the ce ramic coating supports a catalytically active material.
• the embedded resistor may, similar to the macroscopic support, be coated with a ceramic coating to directly support a catalytically active phase while still being embedded in the catalyst material.
• the catalyst material surrounds the embedded resistor and the structured catalyst comprises catalyst material in the form of catalyst pellets, extru- dates or granulates.
• the catalyst material may comprise an appropriate combination of catalyst support and catalytically active phase to facilitate the endothermic reaction.
• the electrically conductive material comprises Fe, Cr, Al or an alloy thereof. Such an alloy may comprise further elements, such as Si, Mn, Y, Zr, C, Co or combina tions thereof.
• the catalytically active material is particles having a size from 5 nm to 250 nm.
• the conductors and the electrically conductive material are made of different materials than the electrically conductive material.
• the conduc- tors may for example be of iron, nickel, aluminum, copper, silver or an alloy thereof.
• the ceramic coating is an electrically insulating material and will typically have a thick ness in the range of around 100 pm, say 10-500 pm.
• the electrically conductive material is advantageously a coherent or consistently intra- connected material in order to achieve electrical conductivity throughout the electri cally conductive material, and thereby achieve thermal conductivity throughout the structured catalyst and in particular providing heating of the catalyst material.
• coherent or consistently intra-connected material it is possible to ensure uniform dis tribution of current within the electrically conductive material and thus uniform distri- bution of heat within the structured catalyst.
• cohesive ent is meant to be synonymous to cohesive and thus refer to a material that is con sistently intra-connected or consistently coupled.
• the effect of the structured catalyst being a coherent or consistently intra-connected material is that a control over the connectivity within the material of the structured catalyst and thus the conductivity of the electrically conductive material is obtained.
• the electrically conductive material is still denoted a coherent or consistently intra-connected material.
• the gas flow over the structured catalyst may be axial or co-axial with the current path through the structured catalyst, perpendicular to the current path or have any other appropriate direction in relation to the current path.
• feed gas is meant to denote a gas having a suitable composi tion for the given endothermic reaction.
• the endothermic reaction is steam me thane reforming this may be typically be hydrocarbons, methane, hydrogen, carbon monoxide, carbon dioxide, steam, and inerts as nitrogen and argon.
• the endo thermic reaction is dehydrogenation it may be a hydrocarbon as propane or styrene together with inert and potentially hydrogen.
• the endothermic reaction is hy drogen cyanide synthesis or a synthesis process for organic nitriles it may be higher hy drocarbons, ammonia, methane, nitrogen, hydrogen, oxygen, and/or inert.
• the endothermic reaction When the endothermic reaction is methanol cracking it may be methanol, steam, carbon monox ide, carbon dioxide, hydrogen, and inert.
• the endothermic reaction When the endothermic reaction is ammonia cracking it may be ammonia, hydrogen, nitrogen, and inert.
• steam reforming is meant to denote a reforming reaction ac cording to one or more of the following reactions:
• Reactions (i) and (ii) are steam methane reforming reactions, whilst reaction (iii) is the dry methane reforming reaction.
• reaction (i) is generalized as:
• steam methane reforming is meant to cover the reactions (i) and (ii)
• steam reforming is meant to cover the reactions (i), (ii) and (iv)
• methanation covers the reverse reaction of reaction (i). In most cases, all of these re actions (i)-(v) are at, or close to, equilibrium at the outlet from the reactor system.
• prereforming is often used to cover the catalytic conversion of higher hy drocarbons according to reaction (iv). Prereforming is typically accompanied by steam reforming and/or methanation (depending upon the gas composition and operating conditions) and the water gas shift reaction. Prereforming is often carried out in adia batic reactors but may also take place in heated reactors.
• Ri and R 2 may be any appropriate group in a hydrocarbon molecule, such as -H, -CH 3 , -CH2, or -CH.
• methanol cracking reaction is accompanied by the water gas shift reaction (v).
• ammonia cracking is meant to denote the following reactions:
• a SMR consists of a number of tubes filled with catalyst pellets placed inside a furnace. The tubes are typically 10-13 meters long and will typically have an inner diameter between 80 and 160 mm. Burners placed in the furnace pro- vide the required heat for the reactions by combustion of a fuel gas. A maximum aver age heat flux of 80000-90000 kcal/h/m 2 of inner tube surface is not uncommon. There is a general limitation to the obtainable heat flux due to mechanical constraints and the capacity is therefore increased by increasing the number of tubes and the furnace size. More details on the SMR type reactor system can be found in the art, e.g. "Syn- thesis gas production for FT synthesis"; Chapter 4, p.258-352, 2004.
• electrically conductive is meant to denote materials with an electrical resis tivity in the range from: 10 5 to 10 8 W-m at 20°C.
• materials that are electrically conductive are e.g. metals like copper, silver, aluminum, chromium, iron, nickel, or al- loys of metals.
• electrically insulating is meant to denote materi als with an electrical resistivity above 10 W-m at 20°C, e.g. in the range from 10 9 to 10 25 W-m at 20°C.
• the reactor system comprises a heat insulation layer between the structured catalyst and the pressure shell
• appropriate heat and electrical insulation between the structured catalyst and the pressure shell is obtained.
• the presence of heat insulating layer between the pressure shell and the structured catalyst assists in avoiding exces sive heating of the pressure shell, and assists in reducing thermal losses to the sur roundings.
• the temperatures of the structured catalyst may reach up to about 1300°C, at least at some parts thereof, but by using the heat insulation layer between the structured catalyst and the pressure shell the temperature of the pressure shell can be kept at significantly lower temperatures of say 500°C or even 100°C, which is advanta geous as typical construction steel materials typically are unsuitable for pressure bear ing application at temperatures above 1000°C.
• a heat insulating layer be- tween the pressure shell and the structured catalyst assists in control of the electrical current within the reactor system, since heat insulation layer is also electrically insulat ing.
• the heat insulation layer could be one or more layers of solid material, such as ce ramics, inert material, bricks or a gas barrier or a combination thereof.
• a purge gas or a confined gas constitutes or forms part of the heat in- sulation layer.
• heat insulating material is meant to de note materials having a thermal conductivity of about 10 W-m _1 -K _1 or below. Exam ples of heat insulating materials are ceramics, bricks, alumina based materials, zirconia based materials and similar.
• any relevant gaps between structured catalyst, the heat insulation layer, the pressure shell, and/or any other components inside the reactor system is filled with inert material, e.g. in the form of inert pellets.
• inert material e.g. in the form of inert pellets.
• Such gaps are e.g. a gap be- tween the lower side of the structured catalyst and the bottom of the pressure shell and a gap between the sides of the structured catalyst and the insulation layer cover ing the inner sides of the pressure shell.
• the inert material may e.g. be a ceramic ma terial in the form of pellets or tiles. The inert material assists in controlling the gas dis tribution through the reactor system and in controlling the flow of the gas through the structured catalyst.
• the inert material typically has a heat insulating effect.
• the pressure shell has a design pressure of between 2 bar and 30 bar.
• the actual operating pressure will be determined by the endothermic reaction, the size of the plants, among other aspects.
• the temperature of the pressure shell can be kept significantly lower than the maximum process temperature. This al lows for having a relative low design temperature of the pressure shell of e.g. 700°C or 500°C or preferably 300°C or 100°C of the pressure shell whilst having maximum pro- cess temperatures of 400°C, or even 900, or even 1100°C, or even up to 1300°C on the structured catalyst. Material strength is higher at the lower of these temperatures (corresponding to the design temperature of the pressure shell as indicated above). This offers advantages when designing the chemical reactor.
• the pressure shell has a design pressure of between 30 bar and 200 bar, preferably between 80 and 180 bar.
• the resistivity of the electrically conductive material is between 10 5 W -m and 10 7 W -m.
• a material with a resistivity within this range provides for an effi- cient heating of the structured catalyst when energized with a power source.
• Graphite has a resistivity of about 10 5 W-m at 20°C
• kanthal has a resistivity of about 10 6 W-m at 20°C
• stainless steel has a resistivity of about 10 7 W-m at 20°C.
• the electrically conductive material may for example be made of FeCrAlloy having a resistivity of ca. 1.5-10 6 W-m at 20°C.
• the pressure shell comprises an inlet for letting in process gas and an outlet for letting out product gas, wherein the inlet is positioned close to a first end of the pressure shell and the outlet is positioned close to a second end of the pressure shell, and wherein the at least two conductors both are connected to the structured catalyst at a position on the structured catalyst closer to the inlet than to the outlet.
• the at least two conductors can be placed in the substantially colder part of the reactor system as the inlet gas will have lower temperature than the product gas, the electrically conductive material will be colder in the colder in the most upstream part of the material due to the heat consumed by the progress of the chemical reac tion, and the feed gas fed led through the inlet may cool the at least two conductors before being heated by the heated structured catalyst further along the path of the gas over the heated structured catalyst. It is an advantage that the temperature of all elec trically conducting elements except the electrically conductive material is kept down in order to protect the connections between the conductors and the structured catalyst.
• the temperature of the conductors and other electrically conducting elements, except the electrically conductive material is relatively low, less limitations on materi als suitable for the conductors and other electrically conducting elements, except the electrically conductive material, exists.
• the temperature of the electrically con ducting elements increase, the resistivity thereof increases; therefore, it is desirable to avoid unnecessary heating of all other parts than the electrically conductive materials within the reactor system.
• the term "electrically conducting elements, except the electrically conductive material" is meant to cover the relevant electrically conducting elements arranged to connect the power supply to the structured catalyst.
• the two conductors of the reactor system may be provided at different ends of the structured catalyst.
• system of the invention may include any appropriate num ber of power supplies and any appropriate number of conductors connecting the power supply/supplies and the electrically conductive material(s) of the structured cat alyst.
• the at least two conductors are led through a pressure shell in a fitting so that the at least two conductors are electrically insulated from the pressure shell.
• the fitting may be, partly, of a plastic and/or ce ramic material.
• the term “fitting” is meant to denote a device that allows for mechani cally connecting two pieces of hardware in a pressure bearing configuration. Thereby, the pressure within the pressure shell may be maintained even though the at least two conductors are lead through it.
• the fittings may be an electri- cally insulating fitting, a dielectric fitting, a power compression seal, a compression fit ting or a flange.
• the pressure shell typically comprises side walls, end walls, flanges and possibly further parts.
• the term “pressure shell” is meant to cover any of these components.
• the pressure shell further comprises one or more inlets close to or in combination with at least one of the fittings in order to allow a cooling gas to flow over, around, close to or inside at least one conductor within said pressure shell.
• the conductors are cooled and thus the temperature that the fitting experi- ences is kept down.
• the conductors may be heated by the feed gas to the reactor system, resistance heating of conductor due to the applied cur rent, and/or heat conduction from the structured catalyst.
• the cooling gas could e.g. be hydrogen, nitrogen, steam, carbon dioxide or mixtures thereof.
• the temperature of the cooling gas at entry into the pressure shell may be e.g. about 100°C or 200°C or 250°C.
• the conductor(s) is (are) hollow so that the cooling gas may flow through the conductor(s) and cool it (them) from within. By keeping the tempera ture of the fitting low, e.g.
• a part of the feed gas such as one of the reactants, is fed to the pressure shell as the cooling gas.
• part of the feed gas or a gas with the same composition as the feed gas is used as cooling gas.
• the reactor system further comprises an inner tube in heat ex change relationship with the structured catalyst, where the inner tube is adapted to withdraw a product gas from the structured catalyst so that the product gas flowing through the inner tube or tubes is in heat exchange relationship with the gas flowing over the structured catalyst, but electrically separated from the structured catalyst.
• This is a layout which here is denoted a bayonet reactor system. In this layout the product gas within the inner tube assists in heating the process gas flowing over the structured catalyst.
• the electrical insulation between the inner tube and the structured catalyst could be gas in the form of a gap or distance between the inner tube and the structured catalyst or inert material loaded around the inner tube and the structured catalyst. The gas may pass through the structured catalyst in an up-flow or a down flow direction.
• connection between the structured catalyst and the at least two conductors is a mechanical connection, a welded connection, a brazed connection or a combination thereof.
• the structured catalyst may comprise terminals physically and electrically connected to the structured catalyst in order to facilitate the electrical connection between the electrically conductive material and the at least two conduc- tors.
• the term "mechanical connection” is meant to denote a connection where two components are held together mechanically, such as by a threaded connection or by clamping, so that a current may run between the components.
• the electrically conductive materials placed in an array of electri- cally conductive materials may be electrically connected to each other.
• the connection between the two or more electrically conductive materials may be by mechanical con nection, clamping, soldering, welding or any combination of these connection meth ods.
• Each electrically conductive material may comprise terminals in order to facilitate the electrical connections.
• the two or more electrically conductive materials may be connected to the power supply in serial or parallel connection.
• the electrical connec tion between the two or more electrically conductive materials is advantageously co herent and uniform along the connection surface between the two or more electrically conductive materials, so that the two or more electrically conductive materials act as a single coherent or consistently intra-connected material; hereby, uniform electrical conductivity throughout the two or more electrically conductive materials is facilitated.
• the structured catalyst may comprise an array of electri cally conductive materials that are not electrically connected to each other. Instead, two or more electrically conductive materials are placed together within the pressure shell, but not connected electrically to each other. In this case, the structured catalyst thus comprises electrically conductive materials connected in parallel to the power supply.
• a ceramic coating, with or without catalytically active material, may be added directly to a metal surface of the electrically conductive material by wash coating.
• the wash coating of a metal surface is a well-known process; a description is given in e.g. Cybul- ski, A., and Moulijn, J. A.," Structured catalysts and reactors", Marcel Dekker, Inc, New York, 1998, Chapter 3, and references herein.
• the ceramic coat may be added to the surface of the electrically conductive material and subsequently the catalytically active material may be added; alternatively, the ceramic coat comprising the catalytically ac tive material is added to the macroscopic structure or electrically conductive material.
• the ceramic coating may for example be an oxide comprising Al, Zr, Mg, Ce and/or Ca.
• Exemplary coatings are calcium aluminate or a magnesium aluminum spinel.
• Such a ceramic coating may comprise further elements, such as La, Y, Ti, K or combinations thereof.
• the ceramic coating is an electrically insulating material and will typically have a thickness in the range of around 100 pm, say 10-500 pm.
• Extruding and sintering or 3D printing a macroscopic structure results in a uniformly and coherently shaped macroscopic structure, which can afterwards be coated with the ceramic coating.
• the electrically conductive material and the ceramic coating may have been sintered in an oxidizing atmosphere in order to form chemical bonds between the ceramic coating and the electrically conductive material; this provides for an especially high heat con- ductivity between the electrically conductive material and the catalytically active ma terial supported by the ceramic coating.
• the structured catalyst is compact in terms of heat transfer to the active catalytic site, and a reactor system housing the structured catalyst may be compact and limited mainly by the rate of the chemical re- action. There is no heat transfer from outside the pressure shell to the structured cata lyst as would be the case through the tube walls to the catalyst within the tubes for the SMRs used in the art of steam reforming.
• the structured catalyst has electrically insulating parts arranged to increase the current path between the conductors to a length larger than the largest dimension of the structured catalyst.
• the provision of a current path between the con ductors larger than the largest dimension of the structured catalyst may be by provi sion of electrically insulating parts positioned between the conductors and preventing the current running through some part of the structured catalyst.
• Such electrically in sulating parts are arranged to increase the current path and thus increase the re sistance through the structured catalyst.
• Non-limiting examples of such insulating parts are cuts, slits, bends, or holes in the electrically conductive material.
• a solid insulating material such as ceramics in cuts or slits in the structure can be used.
• the catalytically active material may advantageously be incorporated in the pores, by e.g. impregna tion.
• a solid insulating material within a cut or slit assists in keeping the parts of the structured catalyst on the sides of the cut or slit from each other.
• the term "largest dimension of the structured catalyst” is meant to denote the largest in- ner dimension of the geometrical form taken up by the structured catalyst. If the struc tured catalyst is box-formed, the largest dimension would be the diagonal from one corner to the farthest corner, also denoted the space diagonal.
• the gas passing through the reactor system is inlet at one end of the reactor system, passes over the structured catalyst once before being outlet from the reactor system.
• Inert material is advanta geously present in relevant gaps between the structured catalyst and the rest of the reactor system to ensure that the gas within the reactor system passes over the struc tured catalyst and the catalyst material herein.
• the length of the gas passage through the structured catalyst is less than the length of the passage of current from one electrode through the structured catalyst and to the next electrode.
• the ratio of the length of the gas passage to the length of the current passage may be less than 0.6, or 0.3, 0.1, or even down to 0.002.
• the structured catalyst has electrically insulating parts arranged to make the current path through the structured catalyst a zigzag path.
• zigzag path and “zigzag route” is meant to denote a path that has corners at variable angles tracing a path from one conductor to another.
• a zigzag path is for example a path going upwards, turning, and subsequently going downwards.
• a zigzag path may have many turns, going upwards and subsequently downwards many times through the structured catalyst, even though one turn is enough to make the path a zigzag path.
• the insulating parts arranged to increase the current path are not necessarily related to the ceramic coating on the electrically conductive material; even though this ceramic coating is also considered electrically insulating, it does not change the length of the current path between the conductors connected to the elec trically conductive material.
• the macroscopic structure has a plurality of parallel channels, a plu- rality of non-parallel channels and/or a plurality of labyrinthic channels, where the channels have walls defining the channels.
• the macro scopic structure has parallel channels, since such parallel channels render a structured catalyst with a very small pressure drop.
• parallel longitudi nal channels are skewed in the longitudinal direction of the macroscopic structure.
• the channels should be appro priate in order to provide a macroscopic structure with a sufficient resistivity.
• the channels could be quadratic (as seen in cross section perpendicular to the channels) and have a side length of the squares of between 1 and 3 mm; however, channels having a maximum extent in the cross section of up to about 4 cm are con- DCvable.
• the walls may e.g.
• the macroscopic structure of the structured catalyst is cross-corrugated.
• the pressure drop from the inlet to the outlet of the reactor system may be reduced considerably compared to a reactor where the catalyst material is in the form of pellets.
• the reactor system further comprises a bed of a second catalyst material upstream the structured catalyst within the pressure shell.
• upstream is seen from the flow direction of the feed gas.
• upstream is here meant to denote that the feed gas is directed through the bed of second cata lyst material prior to reaching the structured catalyst.
• the second catalyst material can be arranged for pre conditioning the feed stream. No specific heating needs to be provided to the bed of second catalyst mate rial; however, the bed of second catalyst material may be heated indirectly if it is in close proximity to the structured catalyst. Alternatively, the second catalyst material may be heated.
• structured catalyst may also be denoted "a first catalyst material” to distinguish it from the second and/or third and/or fourth catalyst material.
• the reactor system further comprises a third catalyst material in the form of catalyst pellets, extrudates or granulates loaded into the channels of the macroscopic structure.
• the reactor system will thus have a catalyt- ically active material in the coating of the macroscopic structure as well as a third cata lyst material in the form catalyst pellets, extrudates or granulates within the channels of the macroscopic structure.
• the pellets are e.g. prepared in a dimension to loosely match the size of channels to form a single string of pellets stacked upon each other within a channel of the macroscopic structure.
• pellets, extrudates or granulates may be prepared in a dimension significantly smaller than the channel size to form a packed bed inside each channel.
• pellet is meant to denote any well-defined structure having a maximum outer dimension in the range of millimeters or centimeters, while “extrudate” and “granulate” are meant to define a catalyst material with a maximum outer dimension defined within a range.
• a bed of fourth catalyst material is placed within the pressure shell and downstream the structured catalyst.
• Such fourth catalyst material may be in the form of catalyst pellets, extrudates or granulates.
• the first, second, third, and fourth catalyst material are catalyst ma terials suitable for the steam reforming reaction, the prereforming reaction, or the wa ter gas shift reaction, the dehydrogenation reaction, the methanol cracking reaction, the ammonia cracking reaction, or the hydrogen cyanide synthesis reaction.
• the catalyst of each catalyst material can be different.
• the geometric surface area of the macroscopic structure is be tween 100 and 3000 m 2 /m 3 , such as between 500 and 1100 m 2 /m 3 .
• the material of the macroscopic structure is chosen as a material arranged to supply a heat flux of 500 W/m 2 to 50000 W/m 2 by resistance heating of the material.
• resistance heating of the material supplies a heat flux of be tween 5 kW/m 2 and 12 kW/m 2 , for example between 8 kW/m 2 and 10 kW/m 2 .
• the heat flux is given as heat per geometric surface area of the surface exposed to the gas.
• the reactor system further comprises a control system arranged to control the electrical power supply to ensure that the temperature of the gas exiting the pressure shell lies in a predetermined range and/or to ensure that the conversion of the feed gas lies in a predetermined range.
• the control of the electrical power sup ply is the control of the electrical output from the power supply.
• the control of the electrical power supply may e.g. be carried out as a control of the voltage and/or cur rent from the electrical power supply, as a control of whether the electrical power sup ply is turned on or off or as a combination hereof.
• the power supplied to the struc- tured catalyst can be in the form of alternating current or direct current.
• the predetermined temperature range of the gas exiting the pressure shell/the reactor system is the range from 200 to 1300°C, depending on the endothermic reaction facili tated.
• the heat added/removed from a re actor system needs to be balanced against the heat consumed/produced by the chemi cal reaction.
• the addition/removal of heat needs to be balanced against the rate of re action and especially the approach to equilibrium as defined by /?, where b is the ratio between the reaction quotient and the equilibrium constant of a reaction.
• a value of b approaching 1 means the reaction mixture is close to equilibrium and values ap proaching 0 means the reaction mixture is far from equilibrium.
• T is the bulk temperature of the gas surrounding the catalyst material used, such as the structured catalyst.
• the cat alyst continuously works towards decreasing NT apP SMR .
• Classically, large scale indus trial SMRs have been designed to obtain an approach to equilibrium of 5-20°C at the outlet thereof.
• the structured catalyst within said reactor system has a ratio be tween the area equivalent diameter of a horizontal cross section through the struc tured catalyst and the height of the structured catalyst in the range from 0.1 to 2.0.
• the area equivalent diameter of the cross section through the reactor system is de fined as the diameter of a circle of equivalent area as the area of the cross section.
• the pressure shell housing the structured catalyst may be relatively small compared to other reactor systems for endothermic reactions such as the current SMRs.
• the gas flows through the reactor system in an upflow or downflow direction, so that the gas flows through channels in the structured catalyst along the height thereof.
• the structured catalyst comprises a number of or an array of macro scopic structures, the individual macroscopic structures within the array may be placed side by side, on top of each other or in a combination thereof.
• the dimen sions of the structured catalyst are the dimensions of the more than one macroscopic structures.
• the structured catalyst comprises two macroscopic structures, each having the height h, put on top of each other, the height of the struc tured catalyst is 2h.
• the volume of the structured catalyst is chosen in consideration of the desired feed conversion and/or temperature out of the reactor system correlated to the heat gen eration capacity of the electrically conductive material.
• the height of the reactor system is between 0.5 and 7 m, more preferably between 0.5 and 3 m. Exemplary values of the height of the reactor system is a height of less than 5 meters, preferably less than 2 m or even 1 m.
• the dimensions of the reactor system and of the structured catalyst within the reactor system are cor related; of course, the pressure shell and heat insulation layer render the reactor sys- tern somewhat larger than the structured catalyst itself.
• industrial scale SMRs are typically constructed of catalyst tubes having a length of 10 m or above to maximize external surface area of the tubes.
• the present invention is advantageous in that such confinement in the design of the reactor system are superfluous.
• Another aspect of the invention relates to a process for carrying out an endothermic reaction of a feed gas in a reactor system comprising a pressure shell housing a struc tured catalyst arranged for catalyzing the endothermic reaction of a feed gas.
• the structured catalyst comprises a macroscopic structure of electrically conductive mate rial, where the macroscopic structure supports a ceramic coating, and where the ce- ramie coating supports a catalytically active material.
• the reactor system is provided with heat insulation between the structured catalyst and the pressure shell.
• the pro cess comprises the following steps:
• the process provides advantages similar to those outlined for the reactor system. However, the process may comprise further steps carried out on the product gas, such as purification, pressurization, heating, cooling, etc. to provide the final product gas for an application downstream the reactor system of this invention.
• the feed gas may comprises individual feed gasses and that the step of pressurizing the feed gas may comprise pressurizing individual feed gasses indi- vidually.
• the order in which the steps of the process are written are not necessarily the order in which the process steps take place, in that two or more steps may take place simultaneously, or the order may be different that indicated above.
• the process comprises the step of pressurizing the gas upstream the pressure shell to a pressure of up to at least 2 bar.
• the chosen operating pressure is defined by the endothermic reaction and the integration of the reactor in the sur rounding process steps.
• the temperature of the feed gas let into the reactor system is between 100°C and 700°C.
• the temperature and the pressure of the feed gas are adjusted to ensure that the feed gas is above the dew point.
• the structured catalyst is heated so that the maximum temperature of the structured catalyst lies between 200°C and 1300°C. The used temperature will be dependent on the endothermic reaction.
• the maximum temperature of the structured catalyst depends upon the material of the electrically conductive material; thus, if the electrically conductive material is of FeCrAlloy, which melts at a temperature of between 1380°C and 1490°C (depending on the actual alloy), the maximum temperature should be somewhat below the melting point, such as at about 1300°C if the melting point of the electrically conductive mate rial is at about 1400°C, as the material will become soft and ductile when approaching the melting point.
• the maximum temperature may additionally be limited by the dura bility of the catalyst material, the coating and the catalytically active material.
• the process according to the invention further comprises the step of inletting a cooling gas through an inlet through the pressure shell in order to allow a cooling gas to flow over at least one conductor and/or fitting.
• the cooling gas may ad- vantageously be hydrogen, nitrogen, steam, carbon dioxide or any other gas suitable for cooling the area or zone around the at least one conductor.
• a part of the feed gas may be fed to the pressure shell as the cooling gas.
• the process further comprises the step of inletting a cooling gas through an inlet through the pressure shell in order to allow a cooling gas to flow over at least one conductor and/or fitting.
• the cooling gas may be any appropriate gas; examples of such gasses are hydrogen, nitrogen, steam, carbon dioxide or mixtures thereof.
• the cooling gas may flow through the conductor(s) and cool it (them) from within; in this case, the conductor(s) need(s) to be hollow to ac- commodate the cooling gas flowing within it/them.
• the endothermic reaction is dehydrogenation of hydrocarbons.
• the catalyst material for the reac tion may be Pt/AI 2 0 3 or Pt-Sn/AI 2 0 3 .
• the catalytically active material may be Pt.
• the maximum temperature of the reactor may be between 500-700°C.
• the pressure of the feed gas may be 2-5 bar.
• the endothermic reaction is cracking of methanol. This reaction takes place according to reaction (v), (ix), and (x).
• the catalyst material for the reaction may be Ni/MgAI 2 0 3 or Cu/Zn/AI 2 0 3 .
• the catalytically active material may be Cu or Ni.
• the maximum temperature of the reactor may be between 200-300°C.
• the pressure of the feed gas may be 2-30 bar, preferably about 25 bar.
• the endothermic reaction is steam reforming of hydrocarbons.
• This reaction takes place according to reaction (i)-(v).
• the catalyst material for the reaction may be N1/AI2O3, Ni/MgAb03, Ni/CaAb03, Ru/MgAb03, or Rh/MgAb03.
• the catalyti- cally active material may be Ni, Ru, Rh, Ir, or a combination thereof.
• the maximum temperature of the reactor may be between 850-1300°C.
• the pressure of the feed gas may be 15-180 bar, preferably about 25 bar.
• the endothermic reaction is ammonia cracking. This reaction takes place according to reaction (xi).
• the catalyst material for the reaction may be Fe, FeCo, or RU/AI2O3.
• the catalytically active material may be Fe or Ru.
• the maximum tempera ture of the reactor may be between 400-700°C.
• the pressure of the feed gas may be 2- 30 bar, preferably about 25 bar.
• the endothermic reaction is the hydrogen cyanide synthesis or a synthesis process for organic nitriles.
• This reaction takes place according to reaction (vi) and (vii).
• the catalyst material for the reaction may be Pt/Ab03.
• the catalytically active material may be Pt, Co, or SnCo.
• the maximum temperature of the reactor may be between 700-1200°C.
• the pressure of the feed gas may be 2-30 bar, preferably about 5 bar.
• the endothermic reaction is aromatization of hydrocarbons. This is advantageously aromatization of higher hydrocarbons.
• Figure la shows a cross section through an embodiment of the inventive reactor sys tem with a structured catalyst comprising an array of macroscopic structures, in a cross section;
• Figure lb shows the reactor system of Figure la with a part of the pressure shell and heat insulation layer removed;
• Figure 2 is an enlarged view of a part of the reactor system
• Figures 3a and 3b show schematic cross sections through an embodiment of the in ventive reactor system comprising a structured catalyst
• Figures 4 and 5 show an embodiment of a structured catalyst with an array of macro scopic structures as seen from above and from the side, respectively;
• Figure 6 shows an embodiment of the structured catalyst of the invention
• Figures 7, 8 and 9 shows embodiments of a structured catalyst with connectors
• Figure 10 shows the required maximum temperature within the reactor system of the invention as a function of the pressure
• Figure 11 is a graph of the approach to equilibrium ( NT app SMR ) of the steam methane reforming reaction for different gas flow rates over a structured catalyst.
• FIG. la shows a cross section through an embodiment of a reactor system 100 ac cording to the invention.
• the reactor system 100 comprises a structured catalyst 10, arranged as an array of macroscopic structures 5. Each macroscopic structure 5 in the array is coated with a ceramic coating impregnated with catalytically active material.
• the reactor system 100 moreover comprises conductors 40, 40' connected to a power supply (not shown in the Figures) and to the structured catalyst 10, viz. the array of macroscopic structures.
• the conductors 40, 40' are led through the wall of a pressure shell 20 housing the structured catalyst and through insulating material 30 on the inner side of the pressure shell, via fittings 50.
• the conductors 40' are connected to the array of macroscopic structures 5 by conductor contact rails 41.
• the electrical power supply supplies a voltage of 26V and a current of 1200A. In another embodiment, the electrical power supply supplies a voltage of 5V and a current of 240A.
• the current is led through electrical conductors 40, 40' to con ductor contact rails 41, and the current runs through the structured catalyst 10 from one conductor contact rail 41, e.g. from the conductor contact rail seen to the left in Figure la, to the other conductor contact rail 41, e.g. the conductor contact rail seen to the right in Figure la.
• the current can be both alternating current, and e.g. run al ternating in both directions, or direct current and run in any of the two directions.
• the macroscopic structures 5 are made of electrically conductive material. Especially preferred is the alloy kanthal consisting of aluminum, iron and chrome.
• the ceramic coating, e.g. an oxide, coated onto the structure catalysts 5 is impregnated with cata- lytically active material.
• the conductors 40, 40' are made in materials like iron, alumi num, nickel, copper or alloys thereof.
• a feed gas enters the reactor system 100 from above as indicated by the arrow 11 and exits the reactor system from the bottom thereof as indicated by the arrow 12.
• Figure lb shows the reactor system 100 of Figure la with a part of the pressure shell 20 and heat insulation 30 layer removed and Figure 2 is an enlarged view of a part of the reactor system 100.
• Figures lb and 2 the connections between conductors 40' and conductor contact rails 41 are shown more clearly than in Figure la.
• the conductors 40 are led through the walls of the pressure shell in a fit ting 50, and that the one conductor 40 is split up into three conductors 40' within the pressure shell.
• the number of conductors 40' may be any ap limbate number, such as smaller than three or even larger than three.
• the conductors 40, 40' are led through the wall of a pressure shell 20 housing the structured catalyst and through in sulating material 30 on the inner side of the pressure shell, via fittings 50.
• Feed gas for steam reforming is inlet into the reactor system 100 via an inlet in the upper side of the reactor system 100 as shown by the arrow 11, and reformed gas exists the reactor system 100 via an outlet in the bottom of the reactor system 100 as shown by the ar row 12.
• one or more additional inlets (not shown in Figures la to 2) advan tageously exist close to or in combination with the fittings 50.
• Such additional inlets al low a cooling gas to flow over, around, close to, or inside at least one conductor within the pressure shell to reduce the heating of the fitting.
• the cooling gas could e.g. be hy drogen, nitrogen, steam, carbon dioxide or mixtures thereof.
• the temperature of the cooling gas at entry into the pressure shell may be e.g. about 100°C.
• inert material (not shown in Fig- ures la-2) is advantageously present between the lower side of the structured catalyst 10 and the bottom of the pressure shell. Moreover, inert material is advantageously present between the outer sides of the structured catalyst 10 of macroscopic struc tures 5 and the insulating material 30. Thus, one side of the insulating material 30 faces the inner side of the pressure shell 20 and the other side of the insulating mate- rial 30 faces the inert material.
• the inert materiel is e.g. ceramic material and may be in the form of pellets.
• FIGS 3a and 3b show schematic cross sections through an embodiment of the in ventive reactor system 100', 100" comprising a structured catalyst 10'.
• the structured catalyst 10' may consist of a single macroscopic structure with ceramic coating sup porting catalytically active material or it may contain two or more macroscopic struc tures.
• Each of the reactor systems 100', 100" comprises a pressure shell 20 and a heat insulation layer 80 between the structured catalyst 10' and the pressure shell 20.
• Inert material 90 can be used to fill the gap between the structured catalyst 10' and the heat insulation layer or the pressure shell 20.
• the inert material 90 is indicated by dotted area; the inert material 90 may be in any appropriate form, e.g. in the form of inert pellets, and it is e.g. of ceramic material.
• the inert material 90 assists in controlling the pressure drop through the reactor system and in controlling the flow of the gas through the reactor system.
• the inert material typically has a heat insulating effect.
• the reactor systems 100', 100" further comprise an inner tube 15 in heat exchange relationship with the structured catalyst 10'.
• the in ner tube 15 is adapted to withdraw a product gas from the structured catalyst 10' so that the product gas flowing through the inner tube or tubes is in heat exchange rela tionship with the gas flowing over the structured catalyst; however, the inner tube 15 is electrically insulated from the structured catalyst 10' by either a heat insulation layer 80, inert material 90, a gap, or a combination.
• This is a layout which is denoted a bayo net reactor system. In this layout, the product gas within the inner tube assists in heat ing the process gas flowing over the macroscopic structure.
• the feed gas enters the reactor system 100', 100" as indicated by the arrow 11, and continues into the structured catalyst 10' as indicated by the arrows 13.
• the gas exiting the structured catalyst 10' is at least partly reformed.
• the at least partly reformed gas flows from the structured catalyst 10' into the inner tube 15 as indicated by the arrows 14, and exits the inner tube as indicated by the arrows 12.
• the heat insulation layer 80 is present between the in- ner tube 15 and the structured catalyst 10', some heat transfer will take place from the gas within the inner tube 15 and the gas within the structured catalyst 10' or upstream the structured catalyst 10'.
• Figures 4 and 5 show an embodiment of a structured catalyst comprising an array of macroscopic structures as seen from above and from the side, respectively.
• Figure 4 shows a structured catalyst 10 comprising an array of macroscopic structure 5 seen from above, viz. as seen from the arrow 11 in Figures la and lb.
• the array has 6 rows, viz. la, lb, lc, Id, le and If, of five macroscopic structures 5.
• the macroscopic struc tures 5 in each row are connected to its neighboring macroscopic structure (s) in the same row and the two outermost macroscopic structures in each row are connected to a conductor contact rail 41.
• the neighboring macroscopic structure 5 in a row of mac roscopic structures are connected to each other by means of a connection piece 3.
• FIG. 5 shows the structured catalyst 10 having an array of macroscopic structures 5 of Figure 4 seen from the side. From Figure 5, it can be seen that each macroscopic structure 5 extends longitudinally perpendicular to the cross section seen in Figure 4. Each macroscopic structure 5 has a slit 60 cut into it along its longitudinal direction (see Figure 5). Therefore, when energized by the power source, the current enters the array of macroscopic structures 5 via a conductor contact rail 41, is led through the first macroscopic structure 5 downwards until the lower limit of the slit 60 and is sub sequently led upwards towards a connection piece 3.
• the current is led via a corre sponding zigzag path, downwards and upwards, through each macroscopic structure 5 in each row la-lf of macroscopic structures 5 in the array 10.
• This configuration advan tageously increases the resistance over the structured catalyst 10.
• FIG. 6 shows a structured catalyst 10 according to the invention in a perspective view.
• the structured catalyst 10 comprises a macroscopic structure that is coated with a ceramic coating impregnated with catalytically active material.
• Within the structured catalyst are channels 70 extending along the longitudinal direction (shown by the ar- row indicate 'h' in Figure 6) of the macroscopic structure 5; the channels are defined by walls 75.
• the walls 75 define a number of parallel, square channels 70 when seen from the direction of flow as indicated by the arrow 12.
• the structured catalyst 10 has a substantially square perimeter when seen from above, defined by the edge lengths el and e2. However, the perimeter could also be circular or another shape.
• the walls 75 of the structured catalyst 10 are of extruded or 3D printed material coated with a ceramic coating, e.g. an oxide, which has been coated onto the macro scopic structure.
• a ceramic coating e.g. an oxide
• the ceramic coating is not shown.
• the ceramic coating is impregnated with catalytically active material.
• the ceramic coating and thus the cat- alytically active material are present on every walls within the structured catalyst 10 over which the gas flow flows during operation and interacts with the heated surface of the structured catalyst and the catalytically active material.
• a hydrocarbon feed gas flows through the channels 70 and interacts with the heated surface of the structured catalyst and with the catalytically active material supported by the ceramic coating.
• a slit 60 has been cut into the struc- tured catalyst 10.
• This slit 60 forces a current to take a zigzag route, in this instance downwards and subsequently upwards, within the macroscopic structure thereby in creasing the current path and thus the resistance and consequently the heat dissipated within the macroscopic structure.
• the slit 60 within the macroscopic structure may be provided with embedded insulating material in order to ensure that no current flows in the transverse direction of the slit 60.
• the channels 70 in the structured catalyst 10 are open in both ends.
• a hydrocarbon feed gas flows through the unit, in the direction shown by arrows 11 and 12 in Figures la and lb, and gets heated via contact with the walls 75 of the channels 70 and by heat radiation. The heat initiates the desired steam reforming process.
• the walls 75 of the channels 70 may e.g. have a thickness of 0.5 mm, and the ceramic coating coated onto the walls 75 may e.g. have a thickness of 0.1 mm.
• the arrows 11 and 12 (see Figures la and lb) indi cate that the flow of the hydrocarbon feed gas is down-flow, the opposite flow direc- tion, viz. an up-flow, is also conceivable.
• Figure 7 shows the structured catalyst 10 of Figures la and lb in a perspective view and with connectors 7 attached.
• the connectors 7 each connects a part of the struc tured catalyst 10 to a conductor 40.
• the conductors 40 are both connected to a power supply (not shown).
• Each of the connectors 7 are connected to an upper part of the structured catalyst.
• an elec trical current is led to the corresponding connector 7 via the conductor and runs through the structured catalyst 10.
• the slit 60 hinders the current flow in a transverse direction (horizontal direction of Figure 7) throughout its lengths along the height h of the structured catalyst 10.
• the current runs in a direction downwards as seen in Figure 7 in the part of the structured catalyst along the slit 60, subsequently it runs transversely to the longitudinal direction below the slit 60 as seen in Figure 7 and finally the current runs upwards in the longitudinal direction of the structured catalyst to the other connector 7.
• the connectors 7 in Figure 7 are mechanically fastened to the structured catalyst by means of i.a. mechanical fastening means such as screws and bolts. However, additional or alternative fastening means are conceivable.
• the electrical power supply generates a voltage of 3V and a current of 400A.
• the connectors 7 are e.g. made in materials like iron, aluminum, nickel, copper or alloys thereof.
• the structured catalyst 10 is coated with a ceramic coating, such as an oxide, supporting the catalytically active material.
• a ceramic coating such as an oxide
• the parts of the structured catalyst 10, which are connected to the connectors 7, should not be coated with an ox ide. Instead, the macroscopic structure of the structured catalyst should be exposed or connected directly to the connectors 7 in order to obtain a good electrical connection between the macroscopic structure and the connector.
• the gas entering into a reactor system housing the structured catalyst 10 would be able to cool the connect ors 7 and the conductors 40.
• the hydrocarbon gas entering into such a re actor system would have a temperature of 400°C or 500°C and would thus keep the connectors 7 and conductors 40 from reaching temperatures much higher than this temperature.
• Figure 8 shows an alternative embodiment of the structured catalyst 10' with connect ors 7' attached.
• the structured catalyst 10' shown in Figure 8 has a square cross sec tion, like the structured catalyst 10 shown in Figures 6 and 7; however, the structured catalyst 10' of Figure 8 does not have any slit cut through it.
• a conductor 40 In the upper and lower end of the macroscopic structure 10' a conductor 40.
• the material of the conductor 40 is e.g. nickel. Alternatively, other appropriate metals could be used as electrical current distributors, or alloys such as FeCrAlloy.
• Connectors 7', 7" in the form of electrical con ducting bars are used for guiding the current across the structured catalyst 10', i.e. the macroscopic structure.
• the connectors 7', 1 are fastened to the conductors 40 and to the structured catalyst 10' by use of mechanical fastening means; however, alternative or additional fastening means are also conceivable.
• Connectors 1 at the lower end of the structured catalyst 10' may be made of a differ- ent material compared to the connectors 7' at the upper end of the structured catalyst 10' as seen in Figure 2.
• the connectors 7' may be of cupper, whilst the connectors 7" may be of nickel. Since nickel has a lower conductivity than cupper, the connectors 1 are larger than the connectors 7'.
• the embodiment shown in Figure 8 is suitable for temperatures below 800°C, such as 600-700°C.
• FIG 9 shows another embodiment of a structured catalyst 10'" with connectors 7"'.
• the structured catalyst 10"' is e.g. the structured catalyst as shown in Figure 6.
• Each of the connectors 7'" has three holes at an upper side thereof for connection to conduc tors (not shown).
• a piece of electrically insulating material 61 is inside the slit 60 (see Figure 6) of the structured catalyst 10'".
• Figure 10 shows the required maximum temperature within the reactor system of the invention as a function of the pressure for pressures of about 30 bar to about 170 bar during steam reforming of a feed gas consisting of 30.08% CH 4 , 69.18% H 2 0, 0.09% H 2 , 0.45% C0 2 , 0.03% Ar, 0.02% CO, 0.15% N 2 to a methane conversion of 88% at a 10°C approach to the steam methane reforming equilibrium.
• the required maximum tem perature increases with pressure due to Le Chatelier's principle. This shows that the high temperatures which can be used in the current invention allows for using pres sures which are significantly higher than the pressures used in a traditional SMR, where the external heating of the tubes prohibit the temperature exceeding ca. 950°C.
• a temperature of 950°C corresponds to 27 barg in Figure 10.
• a maximum temperature of e.g. 1150°C can be used which allows for a pres sure of up to 146 barg with the same conversion of methane as indicated above.
• the reactor systems comprise compact structured catalysts having a high ther mal flux when powered by a power source.
• the dimen sions of the structured catalysts may be chosen relatively freely, so that the structured catalyst may be almost cubic in outer shape or it may be wider than its height.
• the examples all describe operation conditions with high pressure, ranging from 28 bar to 182 bar.
• high pressures are made possible by the configuration of the reactor system since the structured catalyst within the reactor system has high thermal flux upon powering by a power source, is to some extent thermally insulated from the pressure shell, and the pressure drop through the structured catalyst is very low or even non-existing.
• the structured catalyst will obtain the highest temperature within the reactor system, while the pressure shell will have a significantly lower temperature due to the thermal insulation between the macroscopic structure and the pressure shell. Ideally, the temperature of the pressure shell will not exceed 500°C.
• prod uct gas with a high pressure is needed, such as 30 bar or above, the product gas exiting the reactor system can in many cases be used directly, without the use of compres sors.
• the heat insulation layer of the reactor system is a heat insulating mate rial
• the heat insulating material typically makes up most of the space between the structured catalyst and the pressure shell along the walls of the pressure shell so that the feed gas is forced to flow along walls of the macroscopic structure on its way through the pressure shell.
• the examples below (except for the comparative example) all relate to a reactor sys tem with a structured catalyst for steam reforming.
• the structured catalysts described in these examples comprise one or more macroscopic structures.
• the one or more macroscopic structures of the examples below all support a ceramic coating supporting catalytically active material.
• substantially all the surface of the macro scopic structure supports the ceramic coating supporting the catalytically active mate rial; however, at connections points, e.g. between two adjacent macroscopic struc- tures or between a macroscopic structure and a conductor, the macroscopic structure may be free from ceramic coating in order to facilitate connection between a conduc tor and the macroscopic structure.
• a hy drocarbon feed stream comprising i.a. a hydrocarbon gas, hydrogen and steam is fed to the reactor system of the invention.
• the feed stream entering the reactor system is pressurized to a pressure of 28 kg/cm 2 -g and has a temperature of 500°C.
• a structured catalyst in the form of nine macroscopic structures having a square cross section are placed in an array and each macroscopic structure has a size of 0.53 times 0.53 times 2.3 meter.
• Each macroscopic structure additionally has 17778 channels with a square cross section having a side or edge length of 0.32 cm.
• Each macroscopic structure has slits parallel to the longitudinal direction thereof, so that clusters of 5 times 5 channels are formed.
• the clusters are individually insulated from the neighboring cluster, except from the ends, so that the current path through the structured catalyst is a zigzag path.
• a current of 200 A and a voltage of ca. 5.5 kV are applied to each macroscopic structure of the reactor system of the invention in order to heat the structured catalyst and thus the gas passing over the structured catalyst, corresponding to a power supplied in the structured catalysts of 9899 kW.
• the reactor system in the current configuration could have an overall internal diame ter of the reactor system of 3.2 m and a total internal height of 5.5 m when the reactor system is made as a cylindrical reactor system with spherical heads.
• the macroscopic structures are placed in a square orientation having a diag- onal length of 2.3 m.
• inert material is placed around the structured catalyst(s) to close the gap to the insulation material, adjacent to the pressure shell.
• the insulation material in exam ple 1 has a cylindrical form with an internal diameter of 2.5 m and a thickness of 0.35 m.
• the feed gas is heated by the structured catalyst and undergoes steam reforming to a product gas having an exit temperature of 963°C.
• a hy- drocarbon feed stream comprising i.a. a hydrocarbon gas, hydrogen and steam is fed to the reactor system of the invention.
• the feed stream entering the reactor system is pressurized to a pressure of 28 kg/cm 2 -g and has a temperature of 500°C.
• a structured catalyst in the form of 1 macroscopic structure having a square cross section is placed which has a size of 0.4 times 0.4 times 0.35 meter.
• the structured catalyst additionally has 10000 channels with a square cross section having a side or edge length of 0.32 cm.
• the structured catalyst has slits parallel to the longi tudinal direction thereof, so that clusters of 5 times 5 channels are formed.
• the clus ters are individually insulated from the neighboring cluster, except from the ends, so that the current path through the structured catalyst is a zigzag path.
• a current of 200 A and a voltage of ca. 500 V are applied to the structured catalyst of the reactor sys tem of the invention in order to heat the structured catalyst and thus the gas passing over the structured catalyst, corresponding to a power deposited in the structured cat alyst of 99 kW.
• the reactor system in the current configuration could have an overall internal diame ter of the reactor system of 1.2 m and a total internal height of 1.5 m when the reactor system is made as a cylindrical reactor system with spherical heads.
• the structured catalyst has a diagonal length of 0.6 m.
• Inert material is placed around the structured catalysts to close the gap to the insulation material which has an internal diameter of 0.6 m and a thickness of 0.3 m.
• the feed gas is heated by the structured catalyst and undergoes steam reforming to a product gas having an exit temperature of 963°C.
• a hy drocarbon feed stream comprising i.a. a hydrocarbon gas, hydrogen and steam is fed to the reactor system of the invention.
• the feed stream entering the reactor system is pressurized to a pressure of 97 bar, viz. 97 kg/cm 2 -g and has a temperature of 500°C.
• a structured catalyst comprising nine macroscopic structures having a square cross section are placed in an array and each macroscopic structure has a size of 0.53 times 0.53 times 2.3 meter.
• Each macroscopic structure additionally has 17778 channels with a square cross section having a side or edge length of 0.32 cm.
• Each macroscopic structure has slits parallel to the longitudinal direction thereof, so that clusters of 5 times 5 channels are formed.
• the clusters are individually insu lated from the neighboring cluster, except from the ends so that the current path through the structured catalyst is a zigzag path.
• a current of 200 A and a voltage of ca. 5.5 kV are applied to each macroscopic structure in the reactor system of the invention in order to heat the structured catalyst and thus the gas passing over the structured catalyst, corresponding to a power deposited in the structured catalyst of 9899 kW.
• the reactor system in the current configuration could have an overall internal diame ter of the reactor system of 3.2 m and a total internal height of 5.5 m when the reactor system is made as a cylindrical reactor system with spherical heads.
• the structured catalysts are placed in a square orientation having a diagonal length of 2.3 m.
• Inert material is placed around the structured catalysts to close the gap to the insulation material which has an internal diameter of 2.5 m and a thickness of 0.35 m.
• Example 3 During the passage of the feed gas through the reactor system, the feed gas is heated by the structured catalyst and undergoes steam reforming to a product gas having an exit temperature of 1115°C. It is seen from Table 3 that the total flows of the feed gas and the product gas are lower in Example 3 compared to Example 1.
• a hy- drocarbon feed stream comprising i.a. a hydrocarbon gas, hydrogen and steam is fed to the reactor system of the invention.
• the feed stream entering the reactor system is pressurized to a pressure of 28 bar, viz. 28 kg/cm 2 -g and has a temperature of 500°C.
• structured catalyst comprising 25 macroscopic structures having a square cross section are placed in an array and each macroscopic structure has a size of 0.24 times 0.24 times 1.8 meter.
• Each macroscopic structure additionally has 4702 channels with a square cross section having a side or edge length of 0.33 cm in length.
• Each macroscopic structure has slits parallel to the longitudinal direction thereof, so that clusters of 10 times 10 channels are formed. The clusters are individu- ally insulated from the neighboring cluster, except from the ends, so that the current path through the structured catalyst is a zigzag path.
• a current of 500 A and a voltage of ca. 792 V are applied to each macroscopic structure in the reactor system of the in vention in order to heat the structured catalyst and thus the gas passing over the structured catalyst, corresponding to a power deposited in the structured catalyst of 9899 kW.
• the reactor system in the current configuration could have an overall internal diame ter of the reactor system of 2.3 m and a total internal height of 4.1 m when the reactor system is made as a cylindrical reactor system with spherical heads.
• the structured catalysts are placed in a square orientation having a diagonal length of 1.7 m.
• Inert material is placed around the structured catalysts to close the gap to the insulation material which has an internal diameter of 1.8 m and a thickness of 0.25 m.
• a hy drocarbon feed stream comprising i.a. a hydrocarbon gas, hydrogen and steam is fed to the reactor system of the invention.
• the feed stream entering the reactor system is pressurized to a pressure of 182 bar and has a temperature of 500°C.
• a structured catalyst comprising nine macroscopic structures having a square cross section are placed in an array and each macroscopic structure has a size of 0.53 times 0.53 times 2.3 meter.
• Each macroscopic structure additionally has 17778 channels with a square cross section having a side or edge length of 0.32 cm.
• Each macroscopic structure has slits parallel to the longitudinal direction thereof, so that clusters of 5 times 5 channels are formed. The clusters are individually insu lated from the neighboring cluster, except from the ends, so that the current path through the structured catalyst has a zigzag path.
• 5.5 kV are applied to each macroscopic structure in the reactor system of the in vention in order to heat the structured catalyst and thus the gas passing over the structured catalyst, corresponding to a power deposited in the structured catalyst of 9899 kW.
• the reactor system in the current configuration could have an overall internal diame ter of the reactor system of 3.2 m and a total internal height of 5.5 m when the reactor system is made as a cylindrical reactor system with spherical heads.
• the structured catalysts are placed in a square orientation having a diagonal length of 2.3 m.
• Inert material is placed around the structured catalysts to close the gap to the insulation material which has an internal diameter of 2.5 m and a thickness of 0.35 m.
• the feed gas is heated by the structured catalyst and undergoes steam reforming to a product gas having an exit temperature of 1236°C.
• the total flows of the feed gas and the product gas are lower than the total flows of the gasses in Examples 1 and 4.
• the product gas exiting the reactor system is already pressurized to a pressure of 181 bar, it is suited for being input into an ammonia plant without further pressurizing. Thus, no compressors will be needed between the reactor system and the ammonia loop of the ammonia plant. This reduces the overall cost of the plant with a reactor system of the invention and an ammonia loop.
• Example 6 relates to a reactor system comprising a structured catalyst in the form of a macroscopic structure having in total 78540 channels with a total wall length of one channel in the cross section of 0.00628 m each and a length of 2 m, giving a total sur face area of 987 m 2 of catalyst surface.
• a simulation with varying gas flow over the structured catalyst was made where the gas composition in all calculations was 8.8 % H 2 , 56.8% H 2 0, 0.2% N 2 , 0.1% CO, 2.3% C0 2 , and 31.8% CH 4 .
• the Figure shows that at low feed flows (10000 Nm 3 /h), the approach to the equilibrium at the outlet the reactor system is below 5°C, which translate into a hydro carbon conversion of 77%, while at the high flows (150000 Nm 3 /h) the approach to equilibrium is above 60°C, which correspond to a hydrocarbon conversion of only 64%, and the hydrocarbons therefore are used less efficiently.
• the close control of the heat flux in the current invention therefore allows for controlling the approach to equilib- rium closely along the length of the reactor system.
• a general trend in all the curves in Figure 11 is that the approach to equilibrium is continuously decreasing until a pseudo equilibrium is reached, where the heat added and the heat consumed roughly equal each other.
• the approach to equilibrium from this stage is substantially constant or has a slightly increasing development due to the overall increasing temperature of the re- actor system.
• a hydro- carbon feed stream comprising i.a. a hydrocarbon gas and hydrogen is fed to the reac tor system of the invention.
• the feed stream entering the reactor system is pressurized to a pressure of 3.2 bar, viz. 3.2 kg/cm 2 -g, and has a temperature of 500°C.
• a structured catalyst comprising 25 macroscopic structures having a square cross section are placed in an array, where each macroscopic structure has a size of 0.24 times 0.24 times 1.8 meter.
• Each macroscopic structure additionally has 4702 channels with a square cross section having a side or edge length of 0.33 cm in length.
• Each macroscopic structure has slits parallel to the longitudinal direction thereof, so that clusters of 10 times 10 channels are formed. The clusters are individu ally insulated from the neighboring cluster, except from the ends, so that the current path through the structured catalyst is a zigzag path.
• a current of 500 A and a voltage of ca. 787 V are applied to each macroscopic structure in the reactor system of the in vention in order to heat the structured catalyst and thus the gas passing over the structured catalyst, corresponding to a power deposited in the structured catalyst of 9858 kW.
• the reactor system in the current configuration has an overall internal diameter of the reactor system of 2.3 m and a total internal height of 4.1 m when the reactor system is made as a cylindrical reactor system with spherical heads.
• the structured catalyst is placed in a square orientation having a diagonal length of 1.7 m.
• Inert material is placed around the structured catalyst to close the gap to the insula tion material which has an internal diameter of 1.8 m and a thickness of 0.25 m.
• the feed gas is heated by the structured catalyst and undergoes propane dehydrogenation and thermal crack- ing to a product gas having an exit temperature of 600°C.

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• 2019
  • 2019-05-15 EP EP19725314.9A patent/EP3801871A1/en active Pending
  • 2019-05-15 US US17/054,572 patent/US20210113983A1/en active Pending
  • 2019-05-15 CN CN201980034543.6A patent/CN112203757A/zh active Pending
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• 2020
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